Copyright 1911 

BY 

Keystone Fiteproofing Company* 



Increasing Efficiency 

and 

Decreasing Cost 

in 

School House 
Construction 

with 

Keystone Gypsum Blocks 



Keystone Fireproofing Company 

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New York Montreal Philadelphia 

Cincinnati Oklahoma 



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Flues 

Heating and Ventilating 



"HE construction of heating and ventilating 
flues in school houses is one of the most 
important features of the interior of the 
building. Prior to the advent of KEY- 
STONE FLUE BLOCK this problem 
could be solved in only one of two ways — in a 
non-fireproof building, by wood-stud-and-lath en- 
closing tin or galvanized lining; or in a fireproof 
structure bv building the flues of ordinary fireproof 
partition materials or brick, and applying to the inside 
a coat of Portland cement and sand. 

In order to properly control the temperature of 
the school room, particularly in sudden mild weather, 
the heat should enter the room onlv at the points in- 
tended — the register openings. This efficiencv has not 
been secured with either of these forms of con- 
struction. The use of wood-stud-and-lath with metal 
lining offers nothing to oppose the transmission of 
heat at any point of the flue from floor to ceiling, ex- 
cept the plastering, which being composed principallv 
of sand, possesses no value as an insulation. Further- 
more, the life of the metal flue-lining is uncertain at 
best, involving the certainty of repairs in time, and 
always presenting the danger of fire from a defective or 
rusted joint. 



6 FLUES 

While flues built of ordinary fireproof materials 
are superior to those of wood lined with metal, they 
are extremely heavy, and as nearly all of these mate- 
rials are conductors rather than non-conductors of 
heat, fail to solve successfully the problem of prevent- 
ing heat radiation. 

In either case, the cost is excessive. 

KEYSTONE GYPSUM FLUE BLOCKS 
not only successfully meet every condition requisite in 
a material for this purpose, but combine substantial 
economy with this increased efficiency. 

These blocks consist of the same formula as our 
standard KEYSTONE GYPSUM PARTITION 
BLOCKS, but are carefully moulded by hand, with a 
perfectly smooth, even surface on the side forming the 
flue. For the withes or divisions in the flues, a 
thinner block, having the same smooth surface on both 
sides, is used. 

In building the flues 3" hollow blocks should be 
used for ceiling up to 13' and 4" hollow blocks where 
the ceiling heights exceed 13'. For the withes, 1" 
solid blocks are recommended. The blocks should be 
laid up in mortar composed of one part hard or gypsum 
cement plaster to two and one-half parts sand. The 
joints being carefully struck on the inside of the flues, 
no metal lining or cementing is required, and the out- 
side surface of the blocks is ready for brown and finish 
coats of plaster — a scratch coat being unnecessary. 

Aside from the important point of economy, the 



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8 FLUES 

advantages ot KEYSTONE FLUE BLOCKS are 

many. 

ist — They are practically perfect non-conductors, 
insuring against heat radiation. The record of the 
severe official fire test for the New York Bureau ot 
Buildings is prima facie evidence of this, where, not- 
withstanding the intense heat of over 1800 Fahr. to 
which one side of 2" solid and 3" block partitions was 
exposed by direct application of flames, the outer sur- 
face remained sufficiently cool to permit of the bare hand 
being held against it without discomfort. 

2nd — The inseparable bond established between 
the gypsum block and the gypsum mortar eliminates 
the danger of defective joints, and, in consequence, of 
fire. 

3rd — The smooth surface of the blocks, with the 
struck mortar-joints, presents no obstructions to the 
free passage of heat and air, or upon which dust can 
lodge. 

4th — The lightness in weight of this construction 
enables it to be used in any type of building, irrespec- 
tive of floor construction. 

5th — There is no danger of the inside surface 
cracking and falling away as must always occur in time 
where a cement coating is applied. 

6th— The cost of KEYSTONE GYPSUM 
FLUE BLOCKS, set in place, is but a few cents 
more per square foot than ordinary partition construc- 
tion. On the other hand, the difficulty and tedious- 






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ness of plastering the inside of ordinary fireproof flues 
causes this to cost twice as much as ordinary plaster- 
ing, while metal flue lining set in place costs from 20c. 
to 35c. per sq. ft. In other words, KEYSTONE 
GYPSUM FEUE BLOCKS reduce the entire cost 
of this work by from 40% to 65%. 



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Partitions 

A Foreword Regarding Non-Fireproof Schools 

N^-^HE importance of the partitions in a school 
o C j building equals, if it does not exceed, that of 
^^^^ the flue construction. There is no class of 
building that demands every safeguard that modern 
fireproofing affords as much as one housing children. 
Fortunately, the realization of this has become so wide- 
spread that even the smallest communities are willing to 
sacrifice other features in their public schools, and pay 
increased taxes, in order to insure the safety of their 
children during school hours. 

But there are cases, nevertheless, where the lack 
of funds compels the use of non-fireproof construction, 
and in spite of the architect's convictions, he is forced 
to design his building to come within the available 
money. 

Actual fires have shown that the greatest element 
of danger in a non-fireproof building is the wood-stud- 
and-lath partitions. The surfaces of the heavy floors 
and plastered ceilings will resist the attack of flames 
for a considerable time, as there are no angles to start 
the combustion; but in the angle of the floor and ceil- 
ing with the partition, the fire finds the vulnerable point 
to attack. As soon as the flames penetrate the joint 
between the floor and baseboard, the air-space be- 
tween the lath forming the partition acts as a flue, suck- 
ing the fire up through the partitions, and causing it to 



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i 4 PARTITIONS 

mushroom out above the plastered ceiling and attack 
the floor joists above. Hence the usual newspaper 
accounts of fires that " enveloped the entire building 
in flames five minutes after the smoke was first discov- 
ered." 

It is impossible to underestimate the value of 
fireproof floor construction; but when its cost is pro- 
hibitive, the building can be made slow-burning, and 
practically fireproof, by the use of KEYSTONE 
GYPSUM BLOCK PARTITIONS. The extreme 
lightness of these blocks permit their use on wood 
floors without overloading, and while their cost, after 
taking the saving in plastering into consideration, is 
about 15% greater than wood stud partitions, this is in 
most cases more than offset by the economy in the use 
of KEYSTONE FLUE BLOCKS. 

There are three questions that must be conclus- 
ivelv answered regarding any partition material as a 
precedent to its consideration for school house con- 
struction, viz: 

Is it fireproof in every sense that the word implies ? 

Is it sound-proof '? 

Does it form a rigid partition P 

All three of these points are of equal importance. 

The following pages not only offer convincing 
answers to each ot these questions, but demonstrate 
the additional advantages of economy and lightness to 
be secured by the use of KEYSTONE GYPSUM 
BLOCKS. 



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16 PARTITIONS 

Fire- R e si stance 

lEYSTONE GYPSUM BLOCKS consist of 
Nova Scotia gypsum, the purest ever discovered, 
possessing a peculiar chemical property that distinguish- 
es it from any gvpsum found elsewhere, and that gives 
it an unequalled value both as to strength and imper- 
viousness to heat. This rock is mined from our own 
deposits, and calcined by a special process that devel- 
opes in it the highest degree ot fire-resistance that can 
be obtained in anv material used for this purpose. 

Nearly all of the materials in use to-day for fire- 
proofing purposes, while incombustible, fail entirely in 
the realization of the true meaning of the word " fire- 
proof" as applied to modern building construction, as 
thev have no value as fire-resist ants , or non-conductors 
of heat, and are seriously injured or totally destroyed 
by the application of water during or after a fire. 

KEYSTONE GYPSUM BLOCKS, on the 
other hand, are not only incombustible, but afford the 
maximum of efficiency in every feature essential to com- 
plete fire-protection. 

They prevent the passage of nearly all warmth, 
the most severe tests showing heat transmission ot 
only 5%. 

They have a co-efficient of expansion under heat 
of practically zero, insuring against destruction or even 
injury by expansion, the almost universal cause of the 
failure of clav tile, concrete, etc., in every actual fire. 



PARTITIONS 17 

The bond between the block and the mortar is so 
nearly perfect that no weakness develops in the joints 
under the most severe stresses of fire or water. 

They successfully resist the action of a stream ot 
water during or after a fire. 

They form a bond with the plaster so homogene- 
ous that the finish coat, on the reverse side from the 
fire, is not even surface-cracked, and in many cases, 
the plastering has remained intact on the fire side till the 
water has been applied. 

The results of every test, and every actual fire to 
which KEYSTONE GYPSUM BLOCK PAR- 
TITIONS have been subjected during fifteen years, 
have shown that, irrespective of the severity of the fire, 
replastering on the fire side only was necessary to restore 
the partition to its original condition. 

NOTE: Test booklet, containing verbatim reports of the official 
tests for the Bureaus of Buildings of various cities, and describing actual 
fires through which KEYSTONE BLOCKS have passed, will be 
gladly mailed upon request. This booklet will amply repay the time 
spent in its perusal. 



i8 PARTITIONS 

Sound- Deadening 

CHE development of the highest mental efficiency 
demands freedom from distraction. This is 
particularly emphasized in children, whose active and 
untrained minds instinctively seek diversion as a relief 
from the close application of school work. It is obvi- 
ous, therefore, that the use of a material for partitions 
in school houses, that will effectually prevent the com- 
munication of sounds and noises from adjoining rooms, 
is of the greatest importance. 

KEYSTONE GYPSUM BLOCKS are the 
most nearly perfect non-conductors of sound of any 
material on the market, that can be used for this 
purpose. 

Prior to the selection of the partition material for 
the well-known New England Conservatory of Music, 
Boston, in 1902, and because of the importance of 
sound-proofing in a building of this character, a com- 
parative test was conducted by Professor C. L. Norton, 
of the Massachusetts Institute of Technology, to de- 
termine the relative efficiency as non-conductors of 
sound, of every known form of partition construction. 
This test was probablv the only one of any where near 
the scope, and was certainly the most exhaustive, that 
has ever been made, before or since, to determine the 
sound-deadening properties of materials; and as a re- 
sult of it, KEYSTONE GYPSUM BLOCKS were 
used for the partitions throughout the Conservatory. 



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2o PARTITIONS 

This unequalled feature of KEYSTONE 
BLOCKS Is not due solely to the fact that they con- 
sist of gypsum, but to the texture and consistency that 
is peculiar to this material. This has been clearly 
shown by the fact that other blocks, in which plaster 
or gypsum are used in varying proportions, do not 
possess anywhere near the same value as non-con- 
ductors of sound. 

KEYSTONE BLOCKS occupy, to-day, the 
same distinctive position in this respect, that they did 
when Professor Norton's test was made in 1902. 




PARTITIONS 21 

Rigidity 

school building demands a partition construction 
of greater rigidity than almost any other class of 
building, in order to safely carry the weight of the 
blackboards; the more particularly so in that in some 
cases blackboards are hung upon but one side, afford- 
ing no counter-balance to the pull on the partition. 

KEYSTONE GYPSUM BLOCKS form the 
strongest and most rigid partition, for three reasons: 

ist. The blocks themselves are not only strong, 
but possess an element of toughness that makes them 
far superior in ultimate strength, to a hard, brittle 
material. 

2nd. KEYSTONE BLOCKS containing from 
iy 2 to 3 square feet each, a partition built of them 
contains from $o to 66 J ^ per cent less joints. The in- 
creased rigidity which this imparts is obvious. 

3rd. The affinity of gypsum for gypsum is so 
remarkable that a bond is secured between the block 
and the gypsum cement mortar that is nearly homo- 
geneous, the joints having a breaking strength that is 
but little less than the blocks themselves. 

It has been found by experience that, for a given 
ceiling height, KEYSTONE BLOCKS can be safely 
used 1 inch less in thickness than would be necessary 
with other materials. 

The fastening of blackboards to the partitions is 
also simplified, and greater safety insured by the use of 



22 PARTITIONS 

KEYSTONE BLOCKS. This can be accomplish- 
ed in either one of two ways. The toughness of the 
blocks enables them to hold nails or screws; but if this 
method is followed, where heavy blackboards are to be 
carried, courses of solid KEYSTONE BLOCKS 
should be built in where the top and bottom lines of 
fastening will occur, so as to avoid the possibility of 
the nails or screws finding the cores or air spaces in the 
block. Or, as it is possible to cut or drill through 
KEYSTONE BLOCKS the same as wood, without 
danger of cracking or splintering, T-Anchor-bolts can 
be used, the T head taking the pull on the reverse side 
of the partition. The latter is generally considered the 
most practical method, as it eliminates the additional 
cost of the solid blocks and makes it unnecessary to 
establish the exact height or position of blackboards, 
until they are hung. 



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2 4 PARTITIONS 

Lightness 

CHE feature of lightness is desirable in a fire-proof 
building, where the saving in dead load often per- 
mits the use of a lighter beam than would otherwise be 
required, or the reduction of the total section of metal 
in concrete reinforcement; and it is a necessity if fire- 
proof partitions are to be used on wood floor con- 
struction. 

KEYSTONE GYPSUM BLOCKS are the 
lightest^ first-class fire-proofing material on the market. 
The following is a table of standard sizes and weights: 

Weight per sq. ft. 

i^ inch hollow-back (furring). . 41^ pounds 

2 inch hollow-back (furring). . 5 pounds 

2 inch solid 8 pounds 

3 inch solid (roof blocks) ... 13 pounds 

3 inch hollow 8j4 pounds 

4. inch hollow 10 pounds 

5 inch hollow 13 pounds 

6 inch hollow 15 pounds 

8 inch hollow . . . . . . .18 pounds 



PARTITIONS 25 

Econo??iy 

^TT^HILE the care and supervision given to the 
\\) manufacture of KEYSTONE BLOCKS (which 
begins with the selection of the gypsum rock at our 
Nova Scotia mines and is followed through all the sub- 
sequent processes of transportation, storage, crushing, 
calcining and mixing) makes them a trifle higher in first 
cost than some other fire-proof materials, they produce 
the most economical finished partition. Their extreme 
toughness practically eliminates all waste through 
breakage; they can be sawed like wood to break joints, 
fit out around openings, etc., making every piece 
usable. Their lightness, combined with the greatly 
increased area to each block, permits of more than 
double the amount ot work being produced daily by 
each mason. The fewer joints in a partition built of 
them, reduces the mortar by from 50 to 66-^ percent, 
and they save in the cost of plastering, as every block 
is perfect in shape and thickness, and they can be 
erected plumb and true to y& inch grounds, necessitat- 
ing only a light brown and a finish coat of plaster. 



26 COLUMN PROTECTION 

i^JHE vital importance of non-conductivity in any 
^^/ fire-proofing material used for column protection 
can be more clearly realized when it is considered that a 
temperature of 8oo° F. weakens steel 10 per cent, and 
1700 F. causes it to lose 50 per cent of its efficiency. 

In nearly every case, severe fires have demon- 
strated the inadequate protection to the column afforded 
by clay tile and other similar materials, which have 
failed for two causes: 

1st. These materials are nearly all conductors 
instead of non-conductors, offering little or no resis- 
tance to the transmission of heat to the metal that they 
are intended to protect, which quickly loses its 
efficiency under the rapid rise in temperature and 
causes a deflection of the girders that it supports, in- 
juring and often causing the total collapse of the floor 
arches. The result of the tests upon clay tile, con- 
ducted by Mr. C. L. Humphreys, at the Underwriter's 
Laboratories in Chicago, and published in Bulletin No. 
370, of the U. S. Geological Survey, showed that the 
transmission of heat through 5 inch clay tile, was 13 
per cent or nearly three times the conductivity of a j 
inch KEYSTONE BLOCK. 

2nd. The co-efficient of expansion under heat, 
in materials of this character is so high, that the cov- 
ering often buckles and falls from the column even 
before sufficient heat has been comunicated to the steel 
to seriously impair its strength. 



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28 COLUMN PROTECTION 

KEYSTONE GYPSUM BLOCKS are the 

most efficient column protection of any material on the 
market. Everv test and every actual fire that they 
have passed through has proven this conclusively. 

With a conductivity of only 5 per cent it would 
require the impossible temperature of 16,000° F. in a 
building to cause the column to be heated to 8oo° or 
the point causing a 10 per cent loss of efficiency in the 
steel. 

And as there is no expansion whatever with 
KEYSTONE BLOCKS, the protection remains 
firmly in place, under any and all conditions. 



WALL FURRING 29 

^HE same quality that gives to KEYSTONE 
y^J GYPSUM BLOCKS their unequalled efficiency 
as non-conductors of heat, produces a like result in en- 
abling them to resist the transmission of cold. This 
has been determined by liquid air tests, and by actual 
experience in the use of these blocks for insulation in 
cold storage warehouses. 

The use of KEYSTONE GYPSUM FUR- 
RING BLOCKS for wall furring results in a building 
that is warmer in winter and cooler in summer, than 
can be secured with any other material. 

And as these blocks are made with hollow backs, 
they afford the maximum air space with a minimum 
area of contact with the wall. 



30 IN GENERAL 

^T^E prefer, whenever practicable, to bid upon 
\\J KEYSTONE GYPSUM BLOCKS erected in 
place and left ready for plastering. This method not 
only permits us to prove convincingly the economy in 
their use, but carries to the architect and owners our 
unqualified guarantee against any defects in materials or 
workmanship not for one or two years, but as long as 
the building stands. 

Plans sent to any of our sales offices at our ex- 
pense, will be promptly returned with a bona fide bid, 
together with such suggestions as to the specification 
for the work as our wide experience may enable us to 
offer, with a view to increasing its efficiency or decreas- 
ing; its cost. 

Fifteen years experience in the erection as well as 
the manufacture of KEYSTONE BLOCKS has en- 
abled us to build up a field organization that has no 
equal in this country, and the employment of which 
not only insures to the architect the highest standard 
of workmanship and the maximum speed, but a hearty 
co-operation in meeting promptly and successfully the 
many small problems and details that arise on every 
building, and which cannot be foreseen. 

Our Eastern plant, at Chester Pa., is the largest 
factory of its kind in the world. We are therefore al- 
ways in a position to make prompt shipments, a large 
reserve stock of standard sizes being carried to guard 
against the possibility of accidents. 






Corridor Partitions built of Keystone Gvpsum Blocks 



32 IN GENERAL 

In addition to the careful supervision given to the 
manufacture of materials entering into KEYSTONE 
BLOCKS, the blocks themselves are carefully inspect- 
ed at each process. It is this rigid inspection that pre- 
serves the well-known uniformity of quality that has 
always been characteristic of this material. Our im- 
mense drying apparatus, the capacity of w r hich is always 
maintained in excess of the maximum output of the 
moulding plant, enables us to dry every block thorough- 
ly before it is shipped. Experienced inspectors exam- 
ine each car of blocks as it is drawn from the dryers, 
safeguarding against blocks being loaded for shipment 
that have not had every pound of moisture extracted. 

For fifteen years, the KEYSTONE policy has 
been "Satisfaction before Profit", the results of which 
are shown by the fact that, almost without exception, 
every architect who has ever used KEYSTONE 
BLOCKS continues to specify them for all of his work. 



Specifications 



For 



Flues, Partitions, Column Covering, 
Wall Furring 

In 

School Buildings 



FLUES: Construct all heating and ventilating 
flues, where shown on plans, of KEYSTONE 
GYPSUM FLUE BLOCKS. For the walls of flues, 
3" hollow blocks shall be used where ceilings do not ex- 
ceed 13 ft. in height, or \'' hollow blocks for ceilings 
over 13 ft. These blocks shall have a smooth surface 
on the side within the flue, and shall be keyed for plas- 
tering on the outside. 

1'' solid blocks, having this smooth surface on 
both sides, shall be used for the withes. The walls of 
flues and the withes shall be built simultaneously, 
bonded firmly together by breaking joints and left 
ready for brown and finish coats of plaster on the out- 
side surfaces. 

The joints shall be carefully struck and pointed 
on the inside of all flues, leaving no projections of 
mortar. 



34 SPECIFICATIONS 

These blocks shall be laid up in mortar composed 
of one (r) part of gypsum cement plaster, equal to 
"Victor" or "Keystone", to two and one half {2%) 
parts clean sharp sand (measured by bulk) thoroughly 
mixed. No rrrortar shall be re-tempered. 

PARTITIONS: Construct all partitions 
throughout, including skylight curbs and wall of pent 
houses, of KEYSTONE GYPSUM BLOCKS of 
thicknesses marked on drawings or as follows: for par- 
titions not over 13 ft. in height 3" hollow; from 13 to 
17 it., 4" hollow; and where over 17 feet, 6" hollow. 
Form all pipe chases and ducts, except those in brick or 
concrete walls, in same manner as partitions, using 2" 
solid or 3" hollow blocks. Partitions to start on rough 
floors and to be firmly wedged against the under side 
of ceiling above. 

All to be erected in a thoroughly workmanlike 
manner, plumb and true, breaking joints, bonding 
corners and left ready for brown and finish coats of 
plaster. 

This work shall be laid up in mortar composed 
of one (1) part gypsum cement plaster of a quality 
equal to "Victor" or "Keystone" to three (3) parts 
clean, sharp sand, thoroughly mixed. No mortar shall 
be re-tempered. 

COLUMN COVERING AND PILASTERS: 

Cover all exposed interior columns, and form pilasters 
as per details, with 2" solid KEYSTONE GYPSUM 



SPECIFICATIONS 



35 



BLOCKS, laid up in the same mortar as specified for 
partitions, with all corners firmly bonded, and left 
ready for brown and finish coats of plaster. 

WALL FURRING: Furr all exterior walls, 
where shown on drawings, with i ,f hollow-back 
KEYSTONE GYPSUM FURRING BLOCKS; 

this furring shall be set tight against walls, and shall be 
fastened to same, as often as necessary to make a 
thoroughly first-class job, by 20 d nails driven into the 
brick-work, or by building in headers of the same 
blocks secured to the wall by mortar. 

This work shall be laid up in the same mortar as 
specified for partitions, with joints broken and all angles 
bonded, left ready for brown and finish coats of plaster. 

Where furring is shown on drawings to be free- 
standing, use the same thickness of block and erect in 
the same manner as required for partitions ; or 2" solid 
blocks may be used for free-standing furring providing 
that anchors have been built into the wall at proper 
intervals to secure the furring. 

BOOK TILE : For all mansards or other slop- 
ing roofs and dormers, set 3 " KEYSTONE GYPSUM 
ROOF BLOCKS laid dry on T-irons, which shall be 
spaced 24^ \" on centres and shall be furnished and 
erected ready to receive blocks, by the steel contrac- 
tor. After being set dry, these blocks shall be grouted 
by pouring a thin mixture of pure calcined gypsum 
and water into all joints. 



36 SPECIFICATIONS 

( Insert in Carpenters' Specification) 

The carpenter shall furnish the rough frames or 
bucks for all openings in partitions, etc., and shall set 
same in place, properly plumbed ready for the par- 
tition work. Bucks to be the exact width of abutting 
partition block by 3 inches and to have 1 / 2 n x 3/4" 
grounds nailed thereon to receive the ends of the 
blocks. Or bucks may be used \" greater in width 
than the block, and grooved in 3^ r/ to receive the end 
of block and leave y 2 " grounds on either side. 

( Insert in Plastering Specification ) 

The partitions, column covering and wall furring 
are all to be of KEYSTONE GYPSUM BLOCKS, 
and require but one coat to bring up to y 2 " grounds 
ready for the finish coat. 

( Insert in Plumbing and Electrical Specification) 

This contractor shall have all pipes ( or electric 
conduits ) that run in partitions or furring properly 
put in place ahead of the partition work, so that the 
contractor for the partitions shall be able to fit his 
material up to and around same in a workmanlike 
manner. Any cutting or repairing of partitions or 
furring made necessary by failure to do this, or by 
defective work or alterations, shall be done by the 
partition contractor at the expense of the plumbing 
( or electrical ) contractor. 



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9 



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